Flush mounted light fixture assembly and method of installing same

Abstract

The present disclosure relates to a flush mounted light fixture assembly and method of installing same. The light fixture assembly is comprised of a mounting flange and a light fixture housing. The mounting flange comprises one or more securing elements to connect the mounting flange to the wall, and the light fixture housing is adapted to house a light source. The securing elements maintain the position of the light fixture assembly such that a first end of the mounting flange is substantially flush with a first surface of the wall, and the light fixture housing is mountable within the mounting flange such that the light fixture housing does not extend beyond the first end of the mounting flange. The light fixture assembly may also include a lens attachable to the light fixture assembly such that the lens is substantially flush with the first surface of the wall.

Description

TITLEFLUSH MOUNTED LIGHT FIXTURE ASSEMBLY AND METHOD OF INSTALLING SAMETECHNICAL FIELD

[0001] The present application relates generally to recessed lighting fixtures, and more particularly relates to a flush mounted light fixture assembly and method of installing same.BACKGROUND

[0002] Homes and other buildings contain light fixtures of all different shapes and sizes, ranging from large chandeliers to recessed pot lights. Aesthetics are important for people inhabiting and working in these spaces, and the modern aesthetic is trending towards sleeker and more streamlined styles.

[0003] One such style is a recessed lighting fixture. Recessed lighting fixtures typically feature three main components: a housing, a trim, and a bulb. The housing resides within the hole in the ceiling and houses the bulb. The trim, usually made of plastic or metal, fits around the hole in the ceiling and provides a finished look to the light fixture.

[0004] While there are numerous types of recessed lighting fixtures available on the market, they all suffer from the drawback that, no matter how low-profile or recessed they are, they are still visible as light fixtures embedded in a ceiling, thereby creating a visual distraction.

[0005] Therefore, there remains a need for a light fixture that is flush with the ceiling (or other surface) that can “disappear” when the light source is turned off.SUMMARY OF THE DISCLOSURE

[0006] According to one aspect, there is provided a light fixture assembly for installation in an opening defined in a wall, the light fixture assembly comprising: a mounting flange securable in the opening, the mounting flange comprising one or more securing elements to connect the mounting flange to the wall; and a light fixture housing adapted to house a light source, the light fixture housing being mountable within the mounting flange such that the light fixture housing does not extend beyond a first end of the mounting flange, wherein when the light fixture assemblyis installed in the opening, the one or more securing elements maintain the position of the light fixture assembly such that the first end of the mounting flange is substantially flush with a first surface of the wall..

[0007] In an embodiment, the one or more securing elements comprises: a plurality of tabs extending from a perimeter of the mounting flange proximate the first end of the mounting flange; and a plurality of clamping blocks connectable to the mounting flange such that they extend from the perimeter of the mounting flange proximate a second end of the mounting flange, wherein when the light fixture assembly is installed in the opening and the plurality of clamping blocks are connected to the mounting flange, the plurality of tabs are proximate the first surface of the wall, the plurality of clamping blocks are proximate a second surface of the wall, and the plurality of tabs and plurality of clamping blocks are aligned across the wall to create a plurality of aligned pairs of tabs and clamping blocks, and wherein each of the plurality of aligned pairs of tabs and clamping blocks are adapted to connect to each other through the wall. In a further embodiment, the plurality of tabs have a chamfered edge.

[0008] In another embodiment, the one or more securing elements comprises a tapered thread disposed about a perimeter of the mounting flange. In a further embodiment, the mounting flange further comprises a plurality of gripping apertures proximate a second end of the mounting flange.

[0009] In another embodiment, the one or more securing elements comprises a plurality of biased clamps proximate a second end of the mounting flange. In a further embodiment, the one or more securing elements further comprises a plurality of tapered edges disposed about a perimeter of the mounting flange.

[0010] In an embodiment, the light fixture assembly further comprises a lens attachable to the light fixture assembly such that the lens is substantially flush with the first surface of the wall. In a further embodiment, the lens is attachable to the light fixture assembly by threaded connection with the light fixture housing.

[0011] In an embodiment, the light source is an LED printed circuit board.

[0012] In an embodiment, the mounting flange further comprises a plurality of bonding apertures proximate the first end of the mounting flange.

[0013] In an embodiment, the light fixture housing further comprises a heatsink.

[0014] According to another aspect, there is provided a method of installing a light fixture assembly in an opening defined in a wall, the method comprising: inserting a mounting flange in the opening, the mounting flange comprising one or more securing elements; securing the mounting flange in the opening by connecting the mounting flange to the wall with the one or more securing elements; and mounting a light fixture housing within the mounting flange such that the light fixture housing does not extend beyond a first end of the mounting flange, the light fixture housing being adapted to house a light source, wherein the one or more securing elements maintain the position of the light fixture assembly such that the first end of the mounting flange is substantially flush with a first surface of the wall.

[0015] In an embodiment, the one or more securing elements comprises: a plurality of tabs extending from a perimeter of the mounting flange proximate the first end of the mounting flange, each tab comprising an aperture; and a plurality of clamping blocks each comprising an aperture, wherein the step of inserting the mounting flange in the opening comprises placing the plurality of tabs proximate the first surface of the wall, and wherein the step of securing the mounting flange in the opening comprises: connecting the plurality of clamping blocks to the mounting flange such that they extend from the perimeter of the mounting flange proximate a second end of the mounting flange and a second surface of the wall, and aligned with the plurality of tabs across the wall to create a plurality of aligned pairs of tabs and clamping blocks; and inserting a connector through the apertures of each of the plurality of aligned pairs of tabs and clamping blocks.

[0016] In another embodiment, the one or more securing elements comprises a tapered thread disposed about a perimeter of the mounting flange, and the step of securing the mounting flange in the opening comprises screwing the tapered thread into the wall.

[0017] In another embodiment, the one or more securing elements comprises a plurality of biased clamps proximate a second end of the mounting flange, and the step of securing the mounting flange in the opening comprises clamping the plurality of biased clamps against a second surface of the wall. In a further embodiment, the one or more securing elements further comprises a plurality of tapered edges disposed about a perimeter of the mounting flange, and the step ofsecuring the mounting flange in the opening further comprises pressing the plurality of tapered edges into the wall.

[0018] In an embodiment, the method further comprises the step of attaching a lens to the mounting flange such that the lens is substantially flush with the first surface of the wall.

[0019] In an embodiment, the method further comprises the step of attaching a lens to the light fixture housing such that the lens is substantially flush with the first surface of the wall.DESCRIPTION OF THE DRAWINGS

[0020] Fig. 1 is a top perspective exploded view of the main subassemblies of a flush mounted light fixture assembly in accordance with an embodiment of the disclosure.

[0021] Fig. 2 is a bottom perspective exploded view of the main subassemblies of the flush mounted light fixture assembly of Fig. 1 in accordance with an embodiment of the disclosure.

[0022] Fig. 3 is an exploded view of the flush mounted light fixture assembly of Fig. 1 in accordance with an embodiment of the disclosure.

[0023] Fig. 4 is a top perspective view of the flush mounted light fixture assembly of Fig. 1 in accordance with an embodiment of the disclosure.

[0024] Fig. 5 is a bottom perspective view of the flush mounted light fixture assembly of Fig. 1 in accordance with an embodiment of the disclosure.

[0025] Fig. 6 is a side elevational view of the flush mounted light fixture assembly of Fig. 1 in accordance with an embodiment of the disclosure.

[0026] Fig. 7 is a section view of the flush mounted light fixture assembly of Fig. 6 along lines A- A in accordance with an embodiment of the disclosure.

[0027] Fig. 8 is a perspective view of the installation procedure for the mounting flange of the flush mounted light fixture assembly of Fig. 1 in accordance with an embodiment of the disclosure.

[0028] Fig. 9 is a perspective view of the flush mounted light fixture assembly of Fig. 1 installed in a wall in accordance with an embodiment of the disclosure.

[0029] Fig. 10 is a side elevation view of the flush mounted light fixture assembly of Fig. 1 installed in a wall in accordance with an embodiment of the disclosure.

[0030] Fig. 11 is a perspective exploded view of the main subassemblies of a flush mounted light fixture assembly in accordance with an alternative embodiment of the disclosure.

[0031] Fig. 12 is a top perspective view of the flush mounted light fixture assembly of Fig. 11 in accordance with an embodiment of the disclosure.

[0032] Fig. 13 is a bottom perspective view of a mounting flange prior to installation in a wall in accordance with an alternative embodiment of the disclosure.

[0033] Fig. 14 is a bottom perspective view of the mounting flange of Fig. 13 partially installed in a wall in accordance with an embodiment of the disclosure.

[0034] Fig. 15 is a bottom perspective view of the mounting flange of Fig. 13 installed in a wall in accordance with an embodiment of the disclosure.

[0035] Fig. 16 is a bottom perspective view of a mounting flange prior to installation in a wall in accordance with an alternative embodiment of the disclosure.

[0036] Fig. 17 is an exploded view of a flush mounted light fixture assembly in accordance with an alternative embodiment of the disclosure.

[0037] Fig. 18 is a top perspective view of the flush mounted light fixture assembly of Fig. 17 in accordance with an embodiment of the disclosure.

[0038] Fig. 19 is a side elevation section view of the clamping mechanism of a flush mounted light fixture assembly in accordance with an embodiment of the disclosure.

[0039] Fig. 20 is a top perspective exploded view of the main subassemblies of a flush mounted light fixture assembly in accordance with an alternative embodiment of the disclosure.

[0040] Fig. 21 is a bottom perspective exploded view of the main subassemblies of the flush mounted light fixture assembly of Fig. 20 in accordance with an embodiment of the disclosure.

[0041] Fig. 22 is an exploded view of the flush mounted light fixture assembly of Fig. 20 in accordance with an embodiment of the disclosure.

[0042] Fig. 23 is a top perspective view of the flush mounted light fixture assembly of Fig. 20 in accordance with an embodiment of the disclosure.

[0043] Fig. 24 is a bottom perspective view of the flush mounted light fixture assembly of Fig. 20 in accordance with an embodiment of the disclosure.

[0044] Fig. 25 is a side elevational view of the flush mounted light fixture assembly of Fig. 20 in accordance with an embodiment of the disclosure.

[0045] Fig. 26 is a section view of the flush mounted light fixture assembly of Fig. 25 along lines A-A in accordance with an embodiment of the disclosure.

[0046] Fig. 27 is a perspective view of the mounting flange of the flush mounted light fixture assembly of Fig. 20 installed in a wall in accordance with an embodiment of the disclosure.DETAILED DESCRIPTION OF THE INVENTION

[0047] Referring to Figs. 1-10, an exemplary embodiment of a flush mounted light fixture assembly 100 is depicted. The two main subassemblies of the light fixture assembly 100 are the mounting flange 110 and the light fixture housing 130. These subassemblies and their components can generally be seen in Figs. 1-3, and the fully assembled light fixture assembly 100 can generally be seen in Figs. 4-5.

[0048] Referring to the mounting flange 110, it has a first end 114 and a second end 115. When the mounting flange 110 is installed in a ceiling, as is typically the case with light fixtures, the first end 114 would be the bottom (i.e. pointing down from the ceiling towards the room below), and the second end 115 would be the top (i.e. pointing up from the ceiling away from the room below). Given that the present disclosure is not limited to ceiling-mounted light fixture assemblies, thebroader term “wall” as used herein will be understood to encompass ceilings and other surfaces in which the light fixture assemblies of the present disclosure could be mounted.

[0049] In a preferred embodiment, the mounting flange 110 may be made of aluminum and formed by die casting and / or machining. This selection of material and process formation would advantageously provide the mounting flange 110 with the appropriate level of strength and stiffness to securely mount the light fixture housing 130. The mounting flange 110 may also be painted or powder coated to match the colour of the wall 101 in which it is to be installed.

[0050] The outwardly extending tabs 122 are preferably formed from the same material and as one part with the mounting flange 110. Likewise, the inwardly extending tabs 112 (or magnet housings 118, as the case may be) are preferably formed from the same material and as one part with the mounting flange 110. However, both the outwardly extending tabs 122 and inwardly extending tabs 112 (or magnet housings 118) could be formed as separate pieces and joined to the mounting flange 110 by bonding, soldering, or other known means.

[0051] The clamping blocks 120 are preferably formed separately from the mounting flange 110, and may be made of a non-metal material such as nylon or ABS. These non-metal materials are provide strong screw retention, which is advantageous for the reasons described in greater detail below.

[0052] As best seen in Figs. 3, 8, 10, and 22, the clamping blocks 120 are preferably inserted into the apertures 111 after the mounting flange 110 has been inserted into the opening 102 in the wall 101. The position of the clamping blocks 120 prior to being inserted into the apertures 111 (120a) and after being inserted into the apertures 111 (120b) can be seen in Fig. 8. The clamping blocks 120 are inserted through the apertures 111 towards the exterior of the mounting flange 110, in the direction of travel denoted by the arrow 126. Preferably, the trailing end 128 of the clamping blocks 120 is at least slightly larger than the leading end 127 of the clamping blocks 120 so that the trailing end 128 cannot pass through the aperture 111, leading the clamping blocks 120 to be snapped into place in a fixed position.

[0053] As noted above, disposed about the perimeter 116 of the mounting flange 110 at its first end 114 are outwardly extending tabs 122. The tabs 122 have an aperture 123 to receive aconnector 125. The clamping blocks 120 also have an aperture 121 to receive the connector 125. When the clamping blocks 120 are snapped into place as described above, each clamping block120 will be positioned in line with a tab 122. The apertures 121 and 123 on each pair of aligned clamping blocks 120 and tabs 122 are similarly aligned, such that a connector 125 can pass through both apertures. The clamping blocks 120 and tabs 122 may have more than one aligned aperture121 and 123, respectively, such that multiple connectors 125 could pass through the aligned apertures 121 and 123 of an aligned pair of clamping blocks 120 and tabs 122.

[0054] When the mounting block 110 is inserted in an opening 102, the tabs 122 will be placed against a first surface 103 of the wall 101 since they extend from the first end 114 of the mounting flange 110. The first surface 103 is the portion of the wall 101 that faces the direction where the light from the light fixture assembly 100 will be pointing. In the typical case where the wall 101 is a ceiling, the first surface 103 is the visible portion of the ceiling inside a room, and the second surface 104 is the portion of the wall 101 behind the visible ceiling.

[0055] Once the mounting block 110 is inserted in the opening 102 and the clamping blocks 120 are snapped into the apertures 111, the clamping blocks 120 will be abutting the second surface 104 of the wall 101. As seen in Fig. 10, each aligned pair of clamping blocks 120 and tabs 122 are thus sandwiching the wall 101.

[0056] At this stage, the mounting flange 110 may be connected to the wall 101 and secured into the opening 102 by inserting a connector 125 through the aperture 123, through the wall 101, and through the aperture 121. When this is complete, as seen in Fig. 10, the first end 114 of the mounting flange 110 is substantially flush with the first surface 103 of the wall 101. The connector 125 may be any appropriate fastener, but is preferably a self-drilling screw to ensure that the mounting flange 110 is securely connected to the wall 101, and to reduce the risk of crumbling drywall. One example of such a screw is a #6 x 1 1 / 4” flat head drilling screw (McMaster-Carr #94195A130).

[0057] Another feature of the tabs 122 may be a chamfer 124 along the edge of the tabs 122 facing towards the second end 115 of the mounting flange 110. The purpose of the chamfer 124 is to allow the tabs 122 to dimple flush into the first surface 103 of the wall 101 when the connector 125 is threaded through the apertures 121 and 123 and tightened. This allows the head of theconnector 125 to be flush or sub-flush with the first surface 103, thus maintaining the overall appearance of the light fixture assembly 100 as flush with the wall 101. To that end, a dry wall mud 105 (also known as drywall compound or drywall joint compound) may also be applied to the first surface 103 of the wall 101 to cover the tabs 122 and connectors 125.

[0058] The mounting flange 110 may be any suitable size or shape to fit in a similarly sized and shaped opening 102. In a preferred embodiment, the mounting flange 110 may be substantially circular in shape, and between 2” and 8” in diameter. In a particularly preferred embodiment, the mounting flange 110 may be substantially circular in shape, and approximately 4 1 / 8” to 4 1 / 4" in diameter, which would be designed to fit in an opening 102 of approximately 4 1 / 4” to 4 3 / 8”. In this particularly preferred embodiment, the overall thickness of the light fixture assembly 100 may be approximately 31 mm, and the thickness of the clamping blocks 120 may be approximately 9.5 mm.

[0059] Like the mounting flange 110, in a preferred embodiment, the light fixture housing 130 may be made of aluminum and formed by die casting and / or machining. The light fixture housing 130 may also be painted or powder coated to match the colour of the wall 101 in which it is to be installed.

[0060] The light fixture housing 130 has a first end 131 and a second end 132. Similar to the mounting flange 110, when the light fixture assembly 100 is installed in a ceiling, the first end 131 would be the bottom (i.e. pointing down from the ceiling towards the room below), and the second end 132 would be the top (i.e. pointing up from the ceiling away from the room below).

[0061] When the light fixture housing 130 is mounted in the mounting flange 110 (as described in more detail below), the second end 132 of the light fixture housing 130 is proximate the second end 115 of the mounting flange 110, and the first end 131 of the light fixture housing 130 is proximate the first end 114 of the mounting flange 110. However, as seen for example in Figs. 10 and 26, the light fixture housing 130 does not extend beyond the first end 114 of the mounting flange 110 when the light fixture assembly 100 is assembled. This maintains the overall appearance of the light fixture assembly 100 as flush with the wall 101.

[0062] The light fixture housing 130 may be mounted within the mounting flange 110 by any suitable means, including bonding, standard fasteners, or complementary threading on the external perimeter of the light fixture housing 130 and the internal perimeter of the mounting flange 110. The light fixture housing is preferably detachably mounted to the mounting flange 110, but may be permanently or semi -permanently mounted as well.

[0063] One embodiment for mounting the light fixture housing 130 within the mounting flange 110 is best seen in Figs. 1-4 and 9. The mounting flange 110 is provided with inwardly extending tabs 112 proximate the second end 115 of the mounting flange 110. Each of these tabs 112 has a keyhole channel 113, which is a long aperture that narrows in width along its length. The light fixture housing 130 has corresponding connectors 134 at its second end 132 that are sized to fit into the wider part of the keyhole channel 113, but not the narrower part.

[0064] The connectors 134 may be formed as part of the light fixture housing 130 or permanently joined to it, but are preferably shoulder screws that may be threaded into the second end 132 of the light fixture housing 130. One example of such a screw is an M3 low-profile precision shoulder screw (McMaster-Carr #90318 A710).

[0065] To connect the light fixture housing 130 to the mounting flange 110 in this embodiment, the connectors 134 are inserted into the wide end of the keyhole channels 113, and the light fixture housing 130 is rotated so that the connectors 134 travel to the narrower end of the keyhole channels 113. Preferably, the keyhole channels 113 may also have a slight angled ramp within the channel to provide additional seating pressure for the connectors 134. The keyhole channels 113 may be any length, but are preferably long enough to allow the light fixture housing 130 at least a quarter turn.

[0066] In an alternative embodiment for mounting the light fixture housing 130 within the mounting flange 110, the connectors 134 may be replaced by raised tabs that can fit over the corresponding tabs 112 (or similar tabs with or without a keyhole channel 113). When the light fixture housing 130 is inserted into the mounting flange 110 and rotated, the raised tabs in this alternative embodiment of the light fixture housing 130 will sit on top of the tabs 112 and connect the light fixture housing 130 to the mounting flange 110.

[0067] A further alternative embodiment for mounting the light fixture 130 within the mounting flange 110 is shown in Figs. 20-27. In this embodiment, the mounting flange 110 is provided with inwardly extending magnet housings 118 proximate the second end 115 of the mounting flange 110. Each of these magnet housings 118 houses a magnet 117, which may be secured within the magnet housings 118 by any suitable means, including bonding or magnetic force (if the magnet housings 118 are made of a ferrous material).

[0068] The light fixture housing 130 in this embodiment includes an upper cover 139 that is made of a ferrous material, preferably steel. The upper cover may be connected to the base of the light fixture housing 130 by any suitable means, including bonding, standard fasteners, or threading. To connect the light fixture housing 130 to the mounting flange 110 in this embodiment, the light fixture housing 130 is inserted into the mounting flange 110 until the upper cover 139 comes close enough to the magnets 117 to create a magnetic attraction force that holds the light fixture housing 130 and mounting flange 110 together.

[0069] The light fixture housing 130 is adapted to house a light source. In a preferred embodiment, the light source is an LED printed circuit board (PCB) 135. The LED PCB 135 may be connected to the light fixture housing 130 by any suitable means, such as threaded fasteners 136. As the skilled person will appreciate, the LED PCB 135 can be designed in a variety of different ways, including the size and number of LEDs. The LED light source may further be a top lit LED (as seen in Figs. 1-10) or an edge lit LED (as seen in Figs. 20-26). The light fixture housing 130 may also include a reflector 143, which may assist in providing a bright white look to the lens 140 when the light source is illuminated, and may provide (along with the lens 140) the same or a similar appearance as the wall 101 when the light source is not illuminated.

[0070] The light fixture housing 130 may also include a heatsink 133. Where the LED light source is a top lit LED (as seen in Figs. 1-10), the heatsink 133 may be at the second end 132 of the light fixture housing 130, and may be comprised of a series of concentric rings to dissipate some of the heat from the LED PCB 135. Where the LED light source is an edge lit LED (as seen in Figs. 20- 26), the heatsink 133 may be around an outer perimeter of the light fixture housing 130, and may be comprised of a series of fins.

[0071] In some embodiments, the light fixture housing 130 may also include threading 137 on its inner perimeter at its first end 131 (as best seen in Fig. 2). This threading 137 is designed to mate with compatible threads 141 on the external perimeter of a lens 140 (as best seen in Fig. 3). The purpose of the cooperating threads is to provide a seamless integration of the lens 140 into the light fixture assembly 100. In alternative embodiments, the lens 140 may attach to the mounting flange 110 by being press fit inside the mounting flange 110 at its first end 114.

[0072] In further alternative embodiments (as seen, for example, in Figs. 20-26), the lens 140 may be placed within the light fixture housing 130 and held in place between a bottom lip 142 and an upper cover 139 of the light fixture housing 130. In these embodiments, a filler disc 138 may also be placed within the light fixture housing 130 between the lens 140 and the upper cover 139, in order to secure the assembly stackup and assist in maintaining the positioning of the lens 140. As the person skilled in the art will appreciate, the lens 140 may be made of multiple pieces, including one or more of a light guide plate, diffuser, and / or outer lens cover.

[0073] In any case, when the lens 140 is attached to the light fixture assembly 100, the lens 140 is substantially flush with the first surface 103 of the wall 101. The lens 140 may be made of a translucent polycarbonate, and may be painted or powder coated or otherwise treated or formed to match the colour and texture of the wall 101. The lens may further have a protective sticker, substance, or other coating on it prior to painting, powder coating, or other treatment. The skilled person will appreciate that the distance between the LED PCB 135 and the lens 140 should be kept to a minimum, but should also be large enough to eliminate potential hot spots.

[0074] Referring to Figs. 9 and 10, which show the light fixture assembly 100 fully installed, the light source (such as the LED PCB 135) may be connected to a standard junction box 106 as a source of electricity. The junction box 106 may have an external 5-way colour temperature switch and user accessible wiring, including ajunction wire 107. The junction wire 107 may be connected to the fixture wire 108 by a secure fixture wire connector 109.

[0075] When the light fixture assembly 100 is fully installed in the opening 102, it may be painted, powder coated, or otherwise treated at the same time as the wall 101 to ensure a colour and texture match between the light fixture assembly 100 and the wall 101. In this way, when the light source is not illuminated, the light fixture assembly 100 may “disappear” in the wall 101.

[0076] In an alternative embodiment of the light fixture assembly 200 seen in Figs. 11-15, the mounting flange 210 is connected to the wall 101 by a securing element other than the clamping blocks 120, tabs 122, and connectors 125 described above. In this embodiment, the securing element connecting the mounting flange 210 to the wall 101 is a tapered thread 211 disposed around the perimeter 116 of the mounting flange 210.

[0077] In this embodiment, the mounting flange 210 (including the tapered thread 211) is preferably made of plastic, although the light fixture housing 130 is still preferably made of aluminum. To connect the mounting flange 210 to the wall 101, the mounting flange 210 is inserted into the opening 102 and twisted so that the tapered thread 211 engages with the portion of the wall 101 within the opening 102 between the first surface 103 and the second surface 104. In order to assist with gripping the mounting flange 210 during twisting, the mounting flange 210 may include gripping apertures 212.

[0078] Yet another alternative embodiment of a light fixture assembly 300 includes a mounting flange 310 (seen in Figs. 16-19) using biased clamps as a securing element to connect the mounting flange 310 to the wall 101. Referring to Fig. 16, one embodiment of the biased clamps is spring- biased clamps 311 disposed at a second end 115 of the mounting flange 310. After the mounting flange 310 is inserted into the opening 102, the mounting flange 310 may be secured in place and connected to the wall 101 by clamping the spring-biased clamp 311 against the second surface 104 of the wall 101.

[0079] Referring to Figs. 17-19, another embodiment of the biased clamps is lever-biased clamps 312 disposed at a second end 115 of the mounting flange 310 within clamp tabs 318. The lever- biased clamps 312 can slide outwards once the mounting flange 310 is inserted into the opening 102. At that point, a clamp screw 313 can be inserted and tightened against an end of each lever- biased clamp 312. The clamp screw 313 provides screw force in the direction noted by arrow 314 (see Fig. 19), which causes the lever-biased clamp 312 to exert a clamp force in the direction noted by arrow 315 on the second surface 104 of the wall 101. The clamp force connects the mounting flange 310 to the wall 101 and secures it in the opening 102.

[0080] As an additional securing element, the mounting flange 310 may include tapered edges 316 disposed about the perimeter 116 of the mounting flange 310. These tapered edges 316 are pressedinto the wall 101 as the mounting flange 310 is inserted into the opening 102, providing additional connection between the mounting flange 310 and the wall 101 and assisting with the prevention of rotation of the light fixture assembly 300.

[0081] Another feature that may be included with the mounting flange 310 (which could also be included in other embodiments of the mounting flange described in this disclosure) is the bonding apertures 317 proximate the first end 114 of the mounting flange 310. The bonding apertures 317 provide through holes to allow material, such as drywall compound 105, to pass through and bond with the first surface 103 of the wall 101, which in turn increases the connection between the mounting flange 310 and the wall 101.

[0082] In this embodiment, the light fixture housing 130 may be mounted to the mounting flange 310 by virtue of mating connecting tabs - connecting tabs 320 on the light fixture housing 130, and connecting tabs 321 on the mounting flange 310. These mating tabs engage with each other through rotation, like the keyhole channel 113 embodiment described above, but involve a set of overlapping tongues rather than a bolt-in-channel method of connection.

[0083] As noted above, the various embodiments of the light fixture assembly 100, 200, 300 depicted and described in this disclosure would most typically be installed in a ceiling (as depicted, for example, in Figs. 9-10). The skilled person will appreciate, however, that a light fixture assembly 100, 200, 300 of the present disclosure may similarly be installed in a floor, vertical wall (interior or exterior), or other surface. References to the term “wall” throughout this disclosure includes ceilings, floors, dry wall, and other surfaces in which the various embodiments of the light fixture assembly 100, 200, 300 could be installed.

[0084] Additionally, the most typical shape for the light fixture assembly of the present disclosure is cylindrical, which would fit in a circular opening 102. However, the present disclosure contemplates openings 102 of any shape or size, including square, rectangular, oval, etc. Nonetheless, the skilled person will appreciate that certain embodiments described in this disclosure (such as the light fixture assembly 200 shown in Figs. 11-15) may not be compatible with certain shaped openings 102.

[0085] Although the invention has been described with reference to illustrative embodiments, it is to be understood that the invention is not limited to these precise embodiments. Numerous modifications, variations, and adaptations may be made to the particular embodiments of the invention described above without departing from the scope of the invention. The scope of the claims should not be limited by the preferred embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole.

[0086] Immaterial modifications may be made to the embodiments described herein without departing from what is covered by the claims. The indefinite article “a” before a claim feature does not exclude more than one of the feature being present. Each of the individual features described here may be used in one or more embodiments and is not, by virtue only of being described here, to be construed as essential to all embodiments as defined by the claims.

Claims

Claims1 . A light fixture assembly for installation in an opening defined in a wall, the light fixture assembly comprising: a mounting flange securable in the opening, the mounting flange comprising one or more securing elements to connect the mounting flange to the wall; and a light fixture housing adapted to house a light source, the light fixture housing being mountable within the mounting flange such that the light fixture housing does not extend beyond a first end of the mounting flange, wherein when the light fixture assembly is installed in the opening, the one or more securing elements maintain the position of the light fixture assembly such that the first end of the mounting flange is substantially flush with a first surface of the wall.

2. The light fixture assembly of claim 1, wherein the one or more securing elements comprises: a plurality of tabs extending from a perimeter of the mounting flange proximate the first end of the mounting flange; and a plurality of clamping blocks connectable to the mounting flange such that they extend from the perimeter of the mounting flange proximate a second end of the mounting flange, wherein when the light fixture assembly is installed in the opening and the plurality of clamping blocks are connected to the mounting flange, the plurality of tabs are proximate the first surface of the wall, the plurality of clamping blocks are proximate a second surface of the wall, and the plurality of tabs and plurality of clamping blocks are aligned across the wall to create a plurality of aligned pairs of tabs and clamping blocks, and wherein each of the plurality of aligned pairs of tabs and clamping blocks are adapted to connect to each other through the wall.

3. The light fixture assembly of claim 2, wherein the plurality of tabs have a chamfered edge.

4. The light fixture assembly of claim 1 , wherein the one or more securing elements comprises a tapered thread disposed about a perimeter of the mounting flange.

5. The light fixture assembly of claim 4, wherein the mounting flange further comprises a plurality of gripping apertures proximate a second end of the mounting flange.

6. The light fixture assembly of claim 1 , wherein the one or more securing elements comprises a plurality of biased clamps proximate a second end of the mounting flange.

7. The light fixture assembly of claim 6, wherein the one or more securing elements further comprises a plurality of tapered edges disposed about a perimeter of the mounting flange.

8. The light fixture assembly of any of claims 1-7, further comprising a lens attachable to the light fixture assembly such that the lens is substantially flush with the first surface of the wall.

9. The light fixture assembly of claim 8, wherein the lens is attachable to the light fixture assembly by threaded connection with the light fixture housing.

10. The light fixture assembly of any of claims 1-9, wherein the light source is an LED printed circuit board.1 1. The light fixture assembly of any of claims 1-10, wherein the mounting flange further comprises a plurality of bonding apertures proximate the first end of the mounting flange.

12. The light fixture assembly of any of claims 1-11, wherein the light fixture housing further comprises a heatsink.

13. A method of installing a light fixture assembly comprising a mounting flange and a light fixture housing in an opening defined in a wall, the method comprising: inserting the mounting flange in the opening, the mounting flange comprising one or more securing elements; securing the mounting flange in the opening by connecting the mounting flange to the wall with the one or more securing elements; andmounting the light fixture housing within the mounting flange such that the light fixture housing does not extend beyond a first end of the mounting flange, the light fixture housing being adapted to house a light source, wherein the one or more securing elements maintain the position of the light fixture assembly such that the first end of the mounting flange is substantially flush with a first surface of the wall.

14. The method of claim 13, wherein the one or more securing elements comprises: a plurality of tabs extending from a perimeter of the mounting flange proximate the first end of the mounting flange, each tab comprising an aperture; and a plurality of clamping blocks each comprising an aperture, wherein the step of inserting the mounting flange in the opening comprises placing the plurality of tabs proximate the first surface of the wall, and wherein the step of securing the mounting flange in the opening comprises: connecting the plurality of clamping blocks to the mounting flange such that they extend from the perimeter of the mounting flange proximate a second end of the mounting flange and a second surface of the wall, and aligned with the plurality of tabs across the wall to create a plurality of aligned pairs of tabs and clamping blocks; and inserting a connector through the apertures of each of the plurality of aligned pairs of tabs and clamping blocks.

15. The method of claim 13, wherein the one or more securing elements comprises a tapered thread disposed about a perimeter of the mounting flange, and wherein the step of securing the mounting flange in the opening comprises screwing the tapered thread into the wall.

16. The method of claim 13, wherein the one or more securing elements comprises a plurality of biased clamps proximate a second end of the mounting flange, and wherein the step ofsecuring the mounting flange in the opening comprises clamping the plurality of biased clamps against a second surface of the wall.

17. The method of claim 16, wherein the one or more securing elements further comprises a plurality of tapered edges disposed about a perimeter of the mounting flange, and wherein the step of securing the mounting flange in the opening further comprises pressing the plurality of tapered edges into the wall.

18. The method of any of claims 13-17, further comprising the step of attaching a lens to the mounting flange such that the lens is substantially flush with the first surface of the wall.

19. The method of any of claims 13-17, further comprising the step of attaching a lens to the light fixture housing such that the lens is substantially flush with the first surface of the wall.

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